技术领域Technical Field
本发明属于电气工程技术领域，尤其涉及一种自动化变压器质量检测系统。The invention belongs to the technical field of electrical engineering, and in particular relates to an automatic transformer quality detection system.
背景技术Background Art
变压器是一种电气设备，用于改变交流电的电压水平。它通过电磁感应的原理，在输入线圈（称为初级线圈）和输出线圈（称为次级线圈）之间转换电压的大小，同时保持电功率基本不变。变压器可以根据其额定容量和额定电压等级进行分类，例如，按额定容量可分为以下几类：小型变压器，通常指额定电压在为百伏左右的变压器，用于家庭、小型工业用途；中型变压器，通常指额定电压为在千伏左右的变压器，用于工业和分配网；大型变压器，用于大型工业和电力输电，其指额定容量可以达到数十千伏安到数百千伏安以上。A transformer is an electrical device used to change the voltage level of alternating current. It converts the voltage between the input coil (called the primary coil) and the output coil (called the secondary coil) through the principle of electromagnetic induction, while keeping the electrical power basically unchanged. Transformers can be classified according to their rated capacity and rated voltage level. For example, according to the rated capacity, they can be divided into the following categories: small transformers, usually referring to transformers with a rated voltage of about 100 volts, used for household and small industrial purposes; medium-sized transformers, usually referring to transformers with a rated voltage of about 100 volts, used for industry and distribution networks; large transformers, used for large industries and power transmission, and their rated capacity can reach tens of kilovolt-amperes to hundreds of kilovolt-amperes or more.
小型变压器来广泛应用于各类小型电子产品、家用电器以及各种工业模块中，需求量很大。故对于小型变压器生产流水线而言，其单位时间内产量非常大。而受限于生产成本和产量要求，在变压器的生产全流程结束后，往往并不能做到对全部的变压器出厂品质进行统检。现有的主流方法为从每一批次每一条生产线中，按比例抽取样品进行抽检。Small transformers are widely used in various small electronic products, household appliances and various industrial modules, and the demand is very large. Therefore, for the small transformer production line, its output per unit time is very large. However, due to the production cost and output requirements, after the entire production process of the transformer is completed, it is often not possible to conduct a unified inspection of the quality of all transformers before leaving the factory. The existing mainstream method is to take samples in proportion from each batch and each production line for random inspection.
因此，现有的变压器检测方法难以在保持较低的检测成本和具有较高的检测速度之间获取平衡。Therefore, it is difficult for existing transformer detection methods to strike a balance between maintaining a low detection cost and having a high detection speed.
发明内容Summary of the invention
本申请实施例的目的在于提供一种自动化变压器质量检测系统，旨在解决现有的变压器检测方法难以在保持较低的检测成本和具有较高的检测速度之间获取平衡的问题。The purpose of the embodiments of the present application is to provide an automated transformer quality inspection system, aiming to solve the problem that existing transformer inspection methods are difficult to strike a balance between maintaining a low inspection cost and having a high inspection speed.
本申请实施例是这样实现的，一种自动化变压器质量检测系统，所述系统包括：The embodiment of the present application is implemented as follows: an automated transformer quality detection system, the system comprising:
若干个输入检测器、中段检测器、输出控制器、检测流水线、电压输入器、电流检测器以及控制器；Several input detectors, mid-stage detectors, output controllers, detection pipelines, voltage input devices, current detectors and controllers;
每个所述输入检测器均连接有一个变压器输送端，用于对输入到所述检测流水线上的待测变压器进行计数；Each of the input detectors is connected to a transformer delivery terminal for counting the transformers to be tested input to the detection pipeline;
所述检测流水线包括输入段和检测段；所述输入段位于所述检测流水线的上游，用于承载由变压器输送端输入的变压器，所述检测段位于所述检测流水线下游，用于对待测变压器的性能进行测试；The detection pipeline includes an input section and a detection section; the input section is located upstream of the detection pipeline and is used to carry the transformer input from the transformer transmission end; the detection section is located downstream of the detection pipeline and is used to test the performance of the transformer to be tested;
所述输出控制器位于所述检测段的末尾，用于将待测变压器从所述检测流水线中排出；The output controller is located at the end of the detection section and is used to discharge the transformer to be tested from the detection pipeline;
所述中段检测器位于所述检测段的上游，用于控制所述输出控制器，每当所述中段检测器检测到有一个待测变压器进入所述检测段后，控制所述输出控制器排出一个待测变压器，以使所述检测段内的待测变压器数量保持恒定；The middle section detector is located upstream of the detection section and is used to control the output controller. Whenever the middle section detector detects that a transformer to be tested enters the detection section, the output controller is controlled to discharge a transformer to be tested, so that the number of transformers to be tested in the detection section remains constant;
所述电压输入器用于对所述检测段内的待测变压器提供电压输入；The voltage input device is used to provide voltage input to the transformer to be tested in the detection section;
所述电流检测器用于检测所述检测段内的待测变压器的电流输出；The current detector is used to detect the current output of the transformer to be tested in the detection section;
所述控制器与所述输入检测器、所述中段检测器、所述输出控制器、所述电压输入器和所述电流检测器连接，并基于所述电流检测器输出的电流信号判断所述检测段内是否有异常变压器。The controller is connected to the input detector, the middle section detector, the output controller, the voltage input device and the current detector, and determines whether there is an abnormal transformer in the detection section based on the current signal output by the current detector.
优选地，所述检测流水线包含若干个滑动轨槽，用于与待测变压器的各个端子连接，并将待测变压器从所述输入段的上游运送到所述检测段的下游。Preferably, the detection pipeline comprises a plurality of sliding rail grooves for connecting to respective terminals of the transformer to be tested and transporting the transformer to be tested from the upstream of the input section to the downstream of the detection section.
优选地，所述检测流水线包括第一轨槽、第二轨槽、第三轨槽和第四轨槽；Preferably, the detection pipeline includes a first rail groove, a second rail groove, a third rail groove and a fourth rail groove;
所述第一轨槽和第二轨槽用于与待测变压器的原线圈的两个端子分别连接，所述第三轨槽和第四轨槽用于与待测变压器的副线圈的两个端子分别连接；The first rail groove and the second rail groove are used to be connected to two terminals of the primary coil of the transformer to be tested, respectively, and the third rail groove and the fourth rail groove are used to be connected to two terminals of the secondary coil of the transformer to be tested, respectively;
所述电压输入器包括第一电压输入端和第二电压输入端，分别与所述第一轨槽和所述第二轨槽连接，用于在所述第一轨槽和所述第二轨槽之间形成电势差。The voltage input device includes a first voltage input terminal and a second voltage input terminal, which are respectively connected to the first groove and the second groove, and are used to form a potential difference between the first groove and the second groove.
优选地，所述检测段内的待测变压器相互靠近紧密排列。Preferably, the transformers to be tested in the detection section are closely arranged close to each other.
优选地，所述第三轨槽包括N个等长且之间相互绝缘的第一槽段，所述第四轨槽包括N个等长且之间相互绝缘的第二槽段，所述第一槽段和所述第二槽段等长；Preferably, the third rail groove comprises N first groove segments of equal length and insulated from each other, and the fourth rail groove comprises N second groove segments of equal length and insulated from each other, and the first groove segments and the second groove segments are of equal length;
第k+1段所述第一槽段与第k段所述第二槽段之间电连接，；The first slot segment of the k+1th section is electrically connected to the second slot segment of the kth section, ;
所述电流检测器包括第一电流测量端和第二电流测量端，分别与第一段第一槽段和第N段第二槽段连接，用于检测流经自身的电流信号。The current detector comprises a first current measuring end and a second current measuring end, which are respectively connected to the first section first slot segment and the Nth section second slot segment, and are used to detect the current signal flowing through the current detector.
优选地，所述第一槽段的长度满足：Preferably, the length of the first slot section satisfy:
其中，为待测变压器近副线圈端一侧外壳的长度，为所述第三轨槽和第四轨槽之间的间距。in, is the length of the outer shell of the transformer to be tested near the secondary coil end, is the distance between the third rail groove and the fourth rail groove.
优选地，所述输入检测器和所述中段检测器均为光电开关。Preferably, the input detector and the middle section detector are both photoelectric switches.
优选地，所述控制器的外围电路包括：蜂鸣器和警示灯，当所述控制器检测到出现异常变压器后，控制所述蜂鸣器和警示灯进行报警。Preferably, the peripheral circuit of the controller includes: a buzzer and a warning light. When the controller detects an abnormal transformer, the controller controls the buzzer and the warning light to sound an alarm.
优选地，所述控制器的外围电路还包括：Preferably, the peripheral circuit of the controller further includes:
计时器电路，用于对所述控制器提供时间信息。The timer circuit is used to provide time information to the controller.
本申请实施例提供的一种自动化变压器质量检测系统，突出优势在于：通过本申请中提供的检测流水线，能够同时对大量的待测变压器进行同时检测，整体检测速度快，使用便捷，且检测设备生产成本低，利于广泛推广；由于待测变压器在测试段内运行一段时间后才能从流水线中排出，故系统能够对变压器的持续工作能力进行检测，避免传统的检测难以维持教程时间所带来的故障漏检；还能够通过对检测波形的获取，得知该批次和时段内待测变压器的出品品质，检测更加全面充分，良品率显著提高。An automated transformer quality inspection system provided in an embodiment of the present application has the following outstanding advantages: through the inspection pipeline provided in the present application, a large number of transformers to be tested can be inspected simultaneously, the overall inspection speed is fast, the use is convenient, and the production cost of the inspection equipment is low, which is conducive to wide promotion; since the transformer to be tested can only be discharged from the assembly line after running for a period of time in the test section, the system can detect the continuous working ability of the transformer, avoiding the missed faults caused by the difficulty of traditional inspection to maintain the tutorial time; it can also obtain the inspection waveform to know the product quality of the transformer to be tested in the batch and time period, the inspection is more comprehensive and sufficient, and the yield rate is significantly improved.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本申请实施例提供的一种自动化变压器质量检测系统的结构框图；FIG1 is a structural block diagram of an automated transformer quality detection system provided in an embodiment of the present application;
图2为本申请实施例提供的一种变压器的示意图；FIG2 is a schematic diagram of a transformer provided in an embodiment of the present application;
图3为本申请实施例提供的一种待测变压器与检测流水线连接方式的示意图；FIG3 is a schematic diagram of a connection method between a transformer to be tested and a detection pipeline provided in an embodiment of the present application;
图4为一个实施例中计算机设备的内部结构框图。FIG. 4 is a block diagram of the internal structure of a computer device in one embodiment.
具体实施方式DETAILED DESCRIPTION
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.
可以理解，本申请所使用的术语“第一”、“第二”等可在本文中用于描述各种元件，但除非特别说明，这些元件不受这些术语限制。这些术语仅用于将第一个元件与另一个元件区分。举例来说，在不脱离本申请的范围的情况下，可以将第一脚本称为第二脚本，且类似地，可将第二脚本称为第一脚本。It is understood that the terms "first", "second", etc. used in this application may be used herein to describe various elements, but unless otherwise specified, these elements are not limited by these terms. These terms are only used to distinguish a first element from another element. For example, a first script may be referred to as a second script, and similarly, a second script may be referred to as a first script without departing from the scope of this application.
如图1所示，在一个实施例中，提出了一种自动化变压器质量检测系统，具体可以包括：As shown in FIG1 , in one embodiment, an automated transformer quality detection system is proposed, which may specifically include:
若干个输入检测器、中段检测器、输出控制器、检测流水线、电压输入器、电流检测器以及控制器；Several input detectors, mid-stage detectors, output controllers, detection pipelines, voltage input devices, current detectors and controllers;
每个所述输入检测器均连接有一个变压器输送端，用于对输入到所述检测流水线上的待测变压器进行计数；Each of the input detectors is connected to a transformer delivery terminal for counting the transformers to be tested input to the detection pipeline;
所述检测流水线包括输入段和检测段；所述输入段位于所述检测流水线的上游，用于承载由所述变压器输入端输入的变压器，所述检测段位于所述检测流水线下游，用于对待测变压器的性能进行测试；The detection pipeline includes an input section and a detection section; the input section is located upstream of the detection pipeline and is used to carry the transformer input from the transformer input end; the detection section is located downstream of the detection pipeline and is used to test the performance of the transformer to be tested;
所述输出控制器位于所述检测段的末尾，用于将待测变压器从所述检测流水线中排出；The output controller is located at the end of the detection section and is used to discharge the transformer to be tested from the detection pipeline;
所述中段检测器位于所述检测段的上游，用于控制所述输出控制器，每当所述中段检测器检测到有一个待测变压器进入所述检测段后，控制所述输出控制器排出一个待测变压器，以使所述检测段内的待测变压器数量保持恒定；The middle section detector is located upstream of the detection section and is used to control the output controller. Whenever the middle section detector detects that a transformer to be tested enters the detection section, the output controller is controlled to discharge a transformer to be tested, so that the number of transformers to be tested in the detection section remains constant;
所述电压输入器用于对所述检测段内的待测变压器提供电压输入；The voltage input device is used to provide voltage input to the transformer to be tested in the detection section;
所述电流检测器用于检测所述检测段内的待测变压器的电流输出；The current detector is used to detect the current output of the transformer to be tested in the detection section;
所述控制器与所述输入检测器、所述中段检测器、所述输出控制器、所述电压输入器和所述电流检测器连接，并基于所述电流检测器输出的电流信号判断所述检测段内是否有异常变压器。The controller is connected to the input detector, the middle section detector, the output controller, the voltage input device and the current detector, and determines whether there is an abnormal transformer in the detection section based on the current signal output by the current detector.
在本申请实施例中，由于产量往往低于检测速度，故一条检测流水线可以同时有多个输入端，例如一个流水线对接若干生产组，每个生产组的产品输出端均设置有一个计数器，可以进行产量计数。并且，当检测到流水线上产品过多时，可以控制输入端停止输入。检测流水线可以具有驱动和输送能力，可以将如图2所示的变压器以卡接、插接等方式与流水线进行连接。流水线的检测段对其进行检测。本实施例采用的电流检测器用于配合负载检测变压器的负载下的运行能力，其中负载可基于情况进行调整，例如采用阻容电路等。电流信号中出现异常，例如过高、过低、异常波峰或波谷、震荡等情况，均可认为出现异常变压器。In the embodiment of the present application, since the output is often lower than the detection speed, a detection pipeline can have multiple input ends at the same time. For example, a pipeline is connected to several production groups, and the product output end of each production group is provided with a counter, which can count the output. In addition, when it is detected that there are too many products on the pipeline, the input end can be controlled to stop inputting. The detection pipeline can have driving and conveying capabilities, and the transformer shown in Figure 2 can be connected to the pipeline by means of card connection, plug-in connection, etc. The detection section of the pipeline detects it. The current detector used in this embodiment is used to cooperate with the load to detect the operating capacity of the transformer under load, wherein the load can be adjusted based on the situation, such as using a resistor-capacitor circuit. Abnormalities in the current signal, such as too high, too low, abnormal peaks or troughs, oscillations, etc., can all be considered to be abnormal transformers.
在本实施例中，中段检测器可以位于所述检测段流水线的端部，对检测段中的变压器数量进行计数。还可以通过控制器间接控制输出控制器动作，例如，每当有一个待测变压器通过时，将检测流水线中最后一个待测变压器从流水线中取出。即检测段可以为步进式检测，进入一个，退出一个，总体维持检测段内变压器数量稳定。这使得每个变压器被测试的时间相同，在该时间内，可以得到该变压器的持续工作状态能力。输出控制器可以为控制开关门、顶推装置等将待测变压器从流水线中排出，此处不做限制。检测段内待测变压器初始的数量可根据实际情况确定。维持数量稳定的优势在于，检测段内输出的电流值也为恒定的，便于统一标准进行检测，并能够简化检测电路结构。In this embodiment, the middle section detector can be located at the end of the detection section pipeline to count the number of transformers in the detection section. The output controller action can also be indirectly controlled by the controller. For example, whenever a transformer to be tested passes through, the last transformer to be tested in the detection pipeline is taken out of the pipeline. That is, the detection section can be a step-by-step detection, one enters and one exits, and the number of transformers in the detection section is generally maintained stable. This makes the time for each transformer to be tested the same, and within this time, the continuous working state capability of the transformer can be obtained. The output controller can discharge the transformer to be tested from the pipeline for controlling the switch door, the jacking device, etc., which is not limited here. The initial number of transformers to be tested in the detection section can be determined according to actual conditions. The advantage of maintaining a stable number is that the current value output in the detection section is also constant, which is convenient for unified standard detection and can simplify the detection circuit structure.
本实施例中，电压输入器和电流检测器对于变压器的检测方式可以为端子对端子的对接，设置面包板插排，当变压器运动到特定位置时流水线停止传动，并利用设置的大量电压输入端子和电流检测端子与流水线内全部的变压器对接，然后进行检测。In this embodiment, the voltage input device and the current detector can detect the transformer by connecting the terminals to each other, setting a breadboard socket, and when the transformer moves to a specific position, the assembly line stops transmission, and uses a large number of voltage input terminals and current detection terminals to connect with all the transformers in the assembly line, and then perform detection.
作为本申请的一个实施例，突出优势在于：通过本申请中提供的检测流水线，能够同时对大量的待测变压器进行同时检测，整体检测速度快，使用便捷，且检测设备生产成本低，利于广泛推广；由于待测变压器在测试段内运行一段时间后才能从流水线中排出，故系统能够对变压器的持续工作能力进行检测，避免传统的检测难以维持教程时间所带来的故障漏检；还能够通过对检测波形的获取，得知该批次和时段内待测变压器的出品品质，检测更加全面充分，良品率显著提高。As an embodiment of the present application, the outstanding advantages are: through the detection pipeline provided in the present application, a large number of transformers to be tested can be tested simultaneously, the overall detection speed is fast, the use is convenient, and the production cost of the detection equipment is low, which is conducive to wide promotion; since the transformer to be tested can only be discharged from the assembly line after running for a period of time in the test section, the system can detect the continuous working ability of the transformer, avoiding the failure omission caused by the difficulty of traditional detection to maintain the tutorial time; it is also possible to obtain the detection waveform to know the product quality of the transformer to be tested in the batch and time period, the detection is more comprehensive and sufficient, and the yield rate is significantly improved.
在一个优选实施例中，所述检测流水线包含若干个滑动轨槽，用于与待测变压器的各个端子连接，并将待测变压器从所述输入段的上游运送到所述检测段的下游。In a preferred embodiment, the detection pipeline comprises a plurality of sliding rails for connecting to respective terminals of the transformer to be tested and transporting the transformer to be tested from the upstream of the input section to the downstream of the detection section.
在本实施例中，如图3所示，提供了一种流水线的示意图。图3中右向箭头为流水线运动方向。图3中矩形框为变压器本体或变压器固定座、固定框等。为便于检测，流水线设置有1-1，1-2，2-1，2-2这四个插槽，在该实施例中，插槽1-1和1-2用于连接变压器的原边，2-1和2-2用于连接副边。变压器的四个端子分别插接其中。可以理解的是，当变压器有更多或更少端子时，插槽数量可以增多或减少，此处以4个举例。待测变压器在流水线推动或拉动等方式沿流水线从上游至下游滑动。In this embodiment, as shown in FIG3 , a schematic diagram of an assembly line is provided. The right-pointing arrow in FIG3 indicates the direction of movement of the assembly line. The rectangular frame in FIG3 is a transformer body or a transformer fixing seat, a fixing frame, etc. For ease of detection, the assembly line is provided with four slots 1-1, 1-2, 2-1, and 2-2. In this embodiment, slots 1-1 and 1-2 are used to connect the primary side of the transformer, and slots 2-1 and 2-2 are used to connect the secondary side. The four terminals of the transformer are respectively plugged in therein. It can be understood that when the transformer has more or fewer terminals, the number of slots can be increased or decreased, and 4 are taken as an example here. The transformer to be tested slides along the assembly line from upstream to downstream by pushing or pulling the assembly line.
在本申请实施例中，在使用本流水线时，可将以人工的方式或自动化的方式，将变压器的四个端子以卡接、插接在流水线检测槽中，由于变压器一般均为方形，且在生产全部流程完成后其若干个端子的位置相对位置已经固定，故能够便捷地卡接在流水线的检测槽中。In the embodiment of the present application, when using the present assembly line, the four terminals of the transformer can be manually or automatically snapped and plugged into the assembly line detection slot. Since the transformer is generally square and the relative positions of its several terminals are fixed after the entire production process is completed, it can be easily snapped into the inspection slot of the assembly line.
可以理解的是，变压器的触点可以卡接的方式滑动设置在弹性滑槽内，滑槽的材质硬度应高于变压器触点的材质硬度，以减小接触磨损。It is understandable that the contacts of the transformer can be slidably arranged in the elastic sliding groove in a snap-fit manner, and the material hardness of the sliding groove should be higher than the material hardness of the transformer contacts to reduce contact wear.
在一个优选实施例中，所述检测流水线包括第一轨槽和第二轨槽；In a preferred embodiment, the inspection pipeline includes a first rail groove and a second rail groove;
所述第一轨槽和第二轨槽用于与待测变压器的原线圈的两个端子分别连接，所述第三轨槽和第四轨槽用于与待测变压器的副线圈的两个端子分别连接；The first rail groove and the second rail groove are used to be connected to two terminals of the primary coil of the transformer to be tested, respectively, and the third rail groove and the fourth rail groove are used to be connected to two terminals of the secondary coil of the transformer to be tested, respectively;
所述电压输入器包括第一电压输入端和第二电压输入端，分别与所述第一轨槽和所述第二轨槽连接，用于在所述第一轨槽和所述第二轨槽之间形成电势差。The voltage input device includes a first voltage input terminal and a second voltage input terminal, which are respectively connected to the first groove and the second groove, and are used to form a potential difference between the first groove and the second groove.
在本实施例中，为进一步降低成本，优选地，全部待测变压器使用公用电压输入端进行检测，无需布设大量电压输入接触端子以对每个变压器进行分别供电。即使用轨道内提供的电压作为电压源，无需为每个变压器单独配备电压输入端。由于中段检测器的存在，使得检测段内的待测变压器的数量维持恒定，便于检测。In this embodiment, in order to further reduce the cost, preferably, all transformers to be tested use a common voltage input terminal for testing, and there is no need to arrange a large number of voltage input contact terminals to supply power to each transformer separately. That is, the voltage provided in the track is used as the voltage source, and there is no need to equip each transformer with a separate voltage input terminal. Due to the presence of the middle section detector, the number of transformers to be tested in the detection section is kept constant, which is convenient for detection.
通过本实施例的设置方式，系统仅需测量总电流输出，当电流检测器检测到输出异常后，则判断出现了故障变压器。出现的故障一般输入是检测段的第一个待测变压器，例如出现了断路；如第一个变压器检测后没有故障，则可能为检测段的其他变压器故障，原因可能为由于焊点接触不良、绕线短路等原因所产生温升后电流异常。因此可以基于输出电流的波形大致判断出异常情况。另外也能基于输出电流的波形与标准电流的差值，得到本批次变压器的稳定性因数。通过此设置进一步降低了系统的生产和使用成本。Through the setting method of this embodiment, the system only needs to measure the total current output. When the current detector detects an abnormal output, it is determined that a faulty transformer has occurred. The fault generally occurs when the first transformer to be tested in the detection section is input, such as a circuit breaker. If there is no fault after the first transformer is detected, it may be a fault of other transformers in the detection section. The reason may be abnormal current after temperature rise caused by poor contact of the solder joint, short circuit of the winding, etc. Therefore, the abnormal situation can be roughly judged based on the waveform of the output current. In addition, the stability factor of this batch of transformers can be obtained based on the difference between the waveform of the output current and the standard current. This setting further reduces the production and use costs of the system.
在一个优选实施例中，如图3所示，所述检测段内的待测变压器相互靠近紧密排列。In a preferred embodiment, as shown in FIG3 , the transformers to be tested in the detection section are closely arranged close to each other.
在本申请实施例中，为提高流水线检测承载量，待测变压器之间相互紧密排列。In the embodiment of the present application, in order to increase the detection capacity of the assembly line, the transformers to be tested are closely arranged with each other.
在一个优选实施例中，所述检测流水线包括第三轨槽和第四轨槽；In a preferred embodiment, the detection pipeline includes a third rail groove and a fourth rail groove;
所述第三滑槽包括N个等长且之间相互绝缘的第一槽段，所述第四滑槽包括N个等长且之间相互绝缘的第二槽段，所述第一槽段和所述第二槽段等长；The third chute includes N first chute segments of equal length and insulated from each other, and the fourth chute includes N second chute segments of equal length and insulated from each other, and the first chute segments and the second chute segments are of equal length;
第k+1段所述第一槽段与第k段所述第二槽段之间电连接，；The first slot segment of the k+1th section is electrically connected to the second slot segment of the kth section, ;
所述电流检测器包括第一电流测量端和第二电流测量端，分别与第一段第一槽段和第N段第二槽段连接，用于检测流经自身的电流信号。The current detector comprises a first current measuring end and a second current measuring end, which are respectively connected to the first section first slot segment and the Nth section second slot segment, and are used to detect the current signal flowing through the current detector.
在本申请实施例中，为进一步降低设备的生产成本，避免对每个变压器进行单独电流测量所需要的硬件成本以及为了降低测量设备的复杂性，采用了多段轨道设计。如图3所示，轨道2-1和轨道2-2中有若干间断点，通过间断点形成了若干子滑槽，即槽段。上下槽段均由一侧向另一侧排列，并分别为第1段上槽段、第二端上槽段……以此类推。下槽段同理。设置的目的为：当变压器在轨道内滑动时，一个变压器的副边将上下两个对应的槽段连接，形成一个感应电压源，又由于第k+1段上槽段与第k段下槽段之间电连接，使得滑槽内的若干相邻变压器等于相互串联，这使得电流检测器仅需检测整体负载下的总电流，便可获取全部变压器是否正常。从而显著提高了检测的速度。简化了检测结构，无需设置大量分离的电流传感器，降低了成本。In the embodiment of the present application, in order to further reduce the production cost of the equipment, avoid the hardware cost required for measuring the current of each transformer individually, and reduce the complexity of the measuring equipment, a multi-section track design is adopted. As shown in Figure 3, there are several discontinuities in track 2-1 and track 2-2, and several sub-slots, i.e. slot segments, are formed by the discontinuities. The upper and lower slot segments are arranged from one side to the other, and are the upper slot segment of the first segment, the upper slot segment of the second end, and so on. The lower slot segment is the same. The purpose of the setting is: when the transformer slides in the track, the secondary side of a transformer connects the upper and lower corresponding slot segments to form an induced voltage source, and because the upper slot segment of the k+1 segment is electrically connected to the lower slot segment of the kth segment, several adjacent transformers in the chute are equal to each other in series, which makes the current detector only need to detect the total current under the overall load to obtain whether all transformers are normal. Thereby significantly improving the detection speed. The detection structure is simplified, and there is no need to set a large number of separate current sensors, which reduces the cost.
可以理解的是，各个第一段第一槽段和第二槽段连接方式以及上下的相对位置可以基于变压器的具体形态和实际连接关系来确定，此处仅给出一种基础四端子变压器的检测方式，但第一槽段和第二槽段应等长。K的取值为由1至N。当接线端子位置相对变化时，第一槽段的长度也应相对变化。It can be understood that the connection mode of each first section, first slot section and second slot section and the relative position of the upper and lower parts can be determined based on the specific form and actual connection relationship of the transformer. Here, only a basic four-terminal transformer detection method is given, but the first slot section and the second slot section should be of equal length. The value of K is from 1 to N. When the position of the terminal changes relatively, the length of the first slot section should also change relatively.
在一个优选实施例中，所述第一槽段的长度满足：In a preferred embodiment, the length of the first slot segment satisfy:
其中，为待测变压器近副线圈端一侧外壳的长度，为所述第三轨槽和第四轨槽之间的间距。in, is the length of the outer shell of the transformer to be tested near the secondary coil end, is the distance between the third rail groove and the fourth rail groove.
在本申请实施例中，第一槽段和第二槽段等长，变压器为矩形。此时，当变压器紧密排列时，具体几何关系如图3所示。可以理解的是，此处为待测变压器近副线圈端一侧外壳的长度仅为举例，也可为插接变压器或固定变压器的托座的边长。In the embodiment of the present application, the first slot segment and the second slot segment are equal in length, and the transformer is rectangular. At this time, when the transformers are closely arranged, the specific geometric relationship is shown in FIG3. It can be understood that here The length of the shell of the transformer to be tested near the secondary coil end is only an example, and may also be the side length of the bracket of the plug-in transformer or the fixed transformer.
在一个优选实施例中，所述输入检测器和所述中段检测器均为光电开关。In a preferred embodiment, the input detector and the middle section detector are both photoelectric switches.
在本申请实施例中，输入检测器和中段检测器可以为压力触片开关、光电计数器等，优选地，为降低成本选用光电开关，每一个待测变压器通过光电开关后，光电开关出现一次高低电平的波动，进而控制器进行一次计数。In an embodiment of the present application, the input detector and the middle section detector may be a pressure contact switch, a photoelectric counter, etc. Preferably, a photoelectric switch is selected to reduce costs. After each transformer to be tested passes through the photoelectric switch, the photoelectric switch fluctuates between high and low levels, and then the controller performs a count.
在一个优选实施例中，所述控制器的外围电路包括：蜂鸣器和警示灯，当所述控制器检测到出现异常变压器后，控制所述蜂鸣器和警示灯进行报警。In a preferred embodiment, the peripheral circuit of the controller includes: a buzzer and a warning light. When the controller detects an abnormal transformer, the controller controls the buzzer and the warning light to sound an alarm.
在本申请实施例中，控制器可以采用声光报警方式，当出现异常后进行报警。异常可以指电流测量值出现大幅异常波动，电流值过高或过低等。In the embodiment of the present application, the controller may use an audible and visual alarm to give an alarm when an abnormality occurs. The abnormality may refer to a large abnormal fluctuation in the current measurement value, a current value that is too high or too low, etc.
在一个优选实施例中，所述控制器的外围电路还包括：计时器电路，用于对所述控制电路提供时间信息。In a preferred embodiment, the peripheral circuit of the controller further includes: a timer circuit for providing time information to the control circuit.
在本申请实施例中，计时器电路可进行计时，例如采用单片机或石英震荡电路。由于待测变压器进入检测段，或待测变压器被排出检测段需要一定的时间，因此在这个时间内，检测段内的变压器数量是变化的，故不将该时间段作为异常的判断标准。可以利用计数器电路，并利用控制器设置时间阈值，当测量到电流信号异常时间高于阈值时间后，再进行警报。可以理解的，每一个新进入检测段内的变压器的停留时间应大于阈值时间，以免引起误报。In an embodiment of the present application, a timer circuit can be used for timing, for example, by using a single-chip microcomputer or a quartz oscillation circuit. Since it takes a certain amount of time for the transformer to be tested to enter the detection section, or for the transformer to be tested to be discharged from the detection section, the number of transformers in the detection section changes during this time, so this time period is not used as a criterion for abnormal judgment. A counter circuit can be used, and a time threshold can be set using a controller. When the abnormal time of the current signal is measured to be higher than the threshold time, an alarm is issued. It is understandable that the residence time of each new transformer entering the detection section should be greater than the threshold time to avoid false alarms.
在本申请实施例中，控制器可以为PLC控制设备、单片机或计算机设备等，此处不做限制。In the embodiment of the present application, the controller may be a PLC control device, a single chip microcomputer or a computer device, etc., which is not limited here.
图4示出了一个实施例中计算机设备的内部结构图。该计算机设备具体可以是图1中的控制器。如图4所示，该计算机设备包括该计算机设备包括通过系统总线连接的处理器、存储器、网络接口、输入装置和显示屏。其中，存储器包括非易失性存储介质和内存储器。该计算机设备的非易失性存储介质存储有操作系统，还可存储有计算机程序，该计算机程序被处理器执行时，可使得处理器实现本申请实施例所述的控制方法。该内存储器中也可储存有计算机程序，该计算机程序被处理器执行时，可使得处理器执行所述的控制方法。计算机设备的显示屏可以是液晶显示屏或者电子墨水显示屏，计算机设备的输入装置可以是显示屏上覆盖的触摸层，也可以是计算机设备外壳上设置的按键、轨迹球或触控板，还可以是外接的键盘、触控板或鼠标等。FIG4 shows an internal structure diagram of a computer device in an embodiment. The computer device may specifically be the controller in FIG1 . As shown in FIG4 , the computer device includes a processor, a memory, a network interface, an input device, and a display screen connected via a system bus. Among them, the memory includes a non-volatile storage medium and an internal memory. The non-volatile storage medium of the computer device stores an operating system, and may also store a computer program, which, when executed by the processor, enables the processor to implement the control method described in the embodiment of the present application. The internal memory may also store a computer program, which, when executed by the processor, enables the processor to execute the control method. The display screen of the computer device may be a liquid crystal display or an electronic ink display screen, and the input device of the computer device may be a touch layer covered on the display screen, or may be a button, a trackball, or a touchpad provided on the housing of the computer device, or may be an external keyboard, touchpad, or mouse, etc.
本领域技术人员可以理解，图4中示出的结构，仅仅是与本申请方案相关的部分结构的框图，并不构成对本申请方案所应用于其上的计算机设备的限定，具体的计算机设备可以包括比图中所示更多或更少的部件，或者组合某些部件，或者具有不同的部件布置。Those skilled in the art will understand that the structure shown in FIG. 4 is merely a block diagram of a partial structure related to the solution of the present application, and does not constitute a limitation on the computer device to which the solution of the present application is applied. The specific computer device may include more or fewer components than shown in the figure, or combine certain components, or have a different arrangement of components.
应该理解的是，虽然本申请各实施例的流程图中的各个步骤按照箭头的指示依次显示，但是这些步骤并不是必然按照箭头指示的顺序依次执行。除非本文中有明确的说明，这些步骤的执行并没有严格的顺序限制，这些步骤可以以其它的顺序执行。而且，各实施例中的至少一部分步骤可以包括多个子步骤或者多个阶段，这些子步骤或者阶段并不必然是在同一时刻执行完成，而是可以在不同的时刻执行，这些子步骤或者阶段的执行顺序也不必然是依次进行，而是可以与其它步骤或者其它步骤的子步骤或者阶段的至少一部分轮流或者交替地执行。It should be understood that, although each step in the flow chart of each embodiment of the present application is shown in sequence according to the indication of the arrow, these steps are not necessarily performed in sequence according to the order indicated by the arrow. Unless there is clear explanation in this article, the execution of these steps does not have strict order restriction, and these steps can be performed in other orders. Moreover, at least a portion of the steps in each embodiment may include a plurality of sub-steps or a plurality of stages, and these sub-steps or stages are not necessarily performed at the same time, but can be performed at different times, and the execution order of these sub-steps or stages is not necessarily performed in sequence, but can be performed in turn or alternately with at least a portion of other steps or sub-steps or stages of other steps.
本领域普通技术人员可以理解实现上述实施例方法中的全部或部分流程，是可以通过计算机程序来指令相关的硬件来完成，所述的程序可存储于一非易失性计算机可读取存储介质中，该程序在执行时，可包括如上述各方法的实施例的流程。其中，本申请所提供的各实施例中所使用的对存储器、存储、数据库或其它介质的任何引用，均可包括非易失性和/或易失性存储器。非易失性存储器可包括只读存储器（ROM）、可编程ROM（PROM）、电可编程ROM（EPROM）、电可擦除可编程ROM（EEPROM）或闪存。易失性存储器可包括随机存取存储器（RAM）或者外部高速缓冲存储器。作为说明而非局限，RAM以多种形式可得，诸如静态RAM（SRAM）、动态RAM（DRAM）、同步DRAM（SDRAM）、双数据率SDRAM（DDRSDRAM）、增强型SDRAM（ESDRAM）、同步链路（Synchlink）DRAM（SLDRAM）、存储器总线（Rambus）直接RAM（RDRAM）、直接存储器总线动态RAM（DRDRAM）、以及存储器总线动态RAM（RDRAM）等。Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by instructing the relevant hardware through a computer program, and the program can be stored in a non-volatile computer-readable storage medium. When the program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided in this application may include non-volatile and/or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. As an illustration and not limitation, RAM is available in many forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link (Synchlink) DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM).
以上所述实施例的各技术特征可以进行任意的组合，为使描述简洁，未对上述实施例中的各个技术特征所有可能的组合都进行描述，然而，只要这些技术特征的组合不存在矛盾，都应当认为是本说明书记载的范围。The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
以上所述实施例仅表达了本申请的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对本申请专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本申请构思的前提下，还可以做出若干变形和改进，这些都属于本申请的保护范围。因此，本申请专利的保护范围应以所附权利要求为准。The above-mentioned embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the present application. It should be pointed out that, for a person of ordinary skill in the art, several variations and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the attached claims.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202411007038.1ACN118777940B (en) | 2024-07-25 | 2024-07-25 | An automatic transformer quality detection system |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202411007038.1ACN118777940B (en) | 2024-07-25 | 2024-07-25 | An automatic transformer quality detection system |
| Publication Number | Publication Date |
|---|---|
| CN118777940Atrue CN118777940A (en) | 2024-10-15 |
| CN118777940B CN118777940B (en) | 2025-02-11 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202411007038.1AActiveCN118777940B (en) | 2024-07-25 | 2024-07-25 | An automatic transformer quality detection system |
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| CN (1) | CN118777940B (en) |
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